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How An Australian Joinery Manufacturing Company Recouped Its AVR Cost Within 1 Year

 

Case Study For Glavcom

 

Established in 2004, Glavcom incorporated decades of industry experience to establish itself in the joinery manufacturing industry.

 

To be a top player in this industry, Glavcom needed to manufacture a large volume of work and cater to its fast-growing client portfolio. The need to achieve this aim led the esteemed company to install a range of automated woodwork equipment in their manufacturing plant in New South Wales, Australia.

 

In 2014, within Glavcom’s electrical system, a MeterTrac™ Telemetry system was installed to provide continuous and real-time power performance monitoring. Based on the factory’s daily working conditions, this technology analyses detailed power quality measurements for its entire manufacturing operations. 

 

What this innovative system soon revealed—was the hidden risks and extreme severity that the company was unknowingly exposed to.

 

The Problem:

High Reactive Energy & Power Surges

 

High Reactive Energy and Power Surges
High & Unstable Voltage

 

The area of enormous concern is that the incoming voltage supply in their operations was heavily fluctuating by over 35V L-N (or 60V L-L) throughout the day. This voltage variation results in huge instability and is detrimental to the operational efficiency of the automated woodworking equipment. 

 

Glavcom’s load equipment were built to suit a typical European specification of 380/220V. However, according to the data received by MeterTrac™, the average voltage level measured was 248.6V, with spikes up to a maximum of 255.3V—which are well above nominal voltage levels. 

 

Such conditions of voltage fluctuations are clear tell-tale signs of the numerous problems Glavcom faced in its operations. The frequent power surges that they experienced indicated that their equipment was excessively overworking, which increases the possibility of overheating, or even complete failures. This outcome puts all of Glavcom’s equipment on the power circuit at high risk—potentially leading to expensive unplanned downtime.

 

Additionally, the occurrence of unnecessary high reactive energy at the customer endpoints of transmission networks—also adds more costs to the customer’s bills. Considering the increasing average electricity cost in Australia per kWh, this could result in Glavcom having to maintain significantly costlier operations.

 

To achieve a highly optimised level of operational efficiency, it became obvious that Glavcom needed a comprehensive solution—one that would immediately reduce, and effectively stabilise the erratic incoming voltage supply.

 

 

The Ashley Edison (UK) Solution

This immediate need for a reliable voltage optimising solution has led Glavcom towards Ashley Edison.

 

To ensure that Glavcom achieves the best results with completely stabilised voltage, Ashley Edison supplied them with the Protector Series – SESL 3Phase Automatic Voltage Regulator.

 

This Automatic Voltage Regulator (AVR) offers extreme voltage protection for 3 Phase applications that demand highly precise output regulation and ultra-fast response speed. 

 

These voltage regulators are based on the Servo Electronic Digitally Enhanced Design, which boasts reliability for critical applications.

 

 

Complete Voltage Regulating Solution Includes:

Protector Series SESL Automatic Voltage Regulator (Model: SESL Series)
450 KVA x 1 unit

 

Key Features:

  • Servo Electronic Digitally Enhanced Design
  • Stepless Voltage Regulation (± 1% output voltage accuracy)
  • Forced-Air Cooling for improved operational efficiency
  • Fast Response Time (<1.5ms)
  • Inbuilt High Overload Capability (10x max current rating for 2 seconds)
  • Independent Phase Balancing & Control: Automatic voltage sensing & precise regulation to ensure individual phase voltages remain stable – regardless of load change or unbalance.
  • Transient Voltage Surge Protection (TVSS) protects critical loads against harmful high energy surges, transients, and spikes.
  • Wide input voltage tolerance that compensates for low voltage values from 340V, and covers high voltage values up to 460V.

 

The Results

Since the installation of the AVR, Glavcom has seen the AVR cost pay off—in operational effectiveness, and in immense value.

 

Total Voltage Protection

 

  • Power network supply voltage is now completely reduced from a peak of 255.3V (L-N), to an optimal 220V (L-N)
  • Ashley Edison’s AVR now regulates and balances all 3 phases of the factory power supply—tightening it to within ±1% of the power network supply voltage on each of the three phases.
  • For added dependability, each phase is now individually protected by twin module redundancy systems. This means that in the unlikely event of a malfunction, the AVR unit continues to function seamlessly—with no interruption to Glavcom’s operations.
  • With incoming voltage levels now perfectly stabilised on the customer side of the power utility, Glavcom has now full control over their billing meters.

 

Greater Returns on Investment

Ashley Edison AVR provided for a 28% kWh savings per day.

 

 

The average electricity cost in Australia ranges from AU$0.27/kWh up to AU$0.40/kWh.

 

These were the estimated savings:

  • kWh Savings Per Day
    958 kWh – 690 kWh = 268 kWh
  • Cost Savings Per Day
    268 kWh x AU$0.40 = AU$107.20
  • Cost Savings Per Year
    AU$107.20 x 365 days = AU$39,128.00 in 1 Year

Additionally, Glavcom has witnessed an overall improvement of the following:

  • 15% reduction in Peak Demand (average daily kVA)
  • 36% reduction in Reactive Energy (average daily kVARh)
  • 3% improvement in Power Factor (average daily PF)     

Since commissioning the Ashley Edison AVR, the automated woodworking equipment and all loads connected on Glavcom’s power circuit are now fully protected from harmful voltage anomalies. Equipment efficiency is optimizedallowing the company to worry less about downtime, and focus more on moving the needle forward as a business.

 

Not only have they been able to achieve passive savings on maintenance, they have also realized a healthy Return On Investment (ROI) from their AVR installation. 

 

With a fully stabilised and regulated voltage supply, Glavcom continues to gain momentum at the forefront of Australia’s joinery manufacturing industry.

 

 

Conclusion

 

Superb voltage quality plays a huge part in significantly enhancing your electrical systems, enabling you to take your operational efficiency and productivity to a whole different level. This case study demonstrates how a fully protected and regulated voltage supply is vital in promoting outstanding cost-efficiency, and maximum stability.

 

Today, Glavcom has flourished to become one of the elite manufacturers in the industry—delivering the ultimate experience in interior joinery, and serving some of the most iconic buildings in Sydney, Australia.

 

For a comprehensive consultation on how you can effectively optimise operational costs and overcome your power challenges, drop us an email at [email protected].

 

Discover Ashley Edison’s Product Page to learn more about our full range of Automatic Voltage Regulators.

 

“Demand Certainty, With Voltage Stability.”

 

*Tests shown in this case study were conducted during periods when factory conditions were controlled within reason. Results in other situations may vary due to different power transmission networks. MeterTrac MVC230-600 and Ashley Edison AVR surveys are used to model benefits specific to location, plant and equipment loads, and operation patterns.

client
Glavcom, New South Wales, Australia
PROJECT COMPLETION
2014
EQUIPMENT SIZE
AVR | 450KVA, 1 unit
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Three Phase

SESL-H-3P-S Model
Large Capacity Rating
200 to 2,000 KVA

 

Enclosure 335
1000W x 1300H x 580D (mm)
250~300 KVA ± 15%
120~200 KVA ± 20%

 

Enclosure 336
1280W x 1480H x 660D (mm)
400 KVA ± 15%
250 KVA ± 20%

 

Enclosure 337H
1880W x 1950H x 880D (mm)
500 KVA ± 15%
300 KVA ± 20%

 

Enclosure 339
1470W x 1950H x 1340D (mm)
600 ~ 1,500 KVA ± 15%
400 ~ 1,000 KVA ± 20%
300 ~ 750 KVA ± 25%
300 ~ 600 KVA ± 30%

Three Phase

SES-H-3P-S Model
Added I/P Breaker Protection
60 to 1,000 KVA

 

Enclosure 333
490W x 800H x 990D (mm)
≤ 100 KVA ± 15%

 

Enclosure 334
540W x 900H x 1000D (mm)
120 – 150 KVA ± 15%

 

Enclosure 335
1000W x 1300H x 580D (mm)
180 – 300 KVA ± 15%
120 – 200 KVA ± 20%
120 – 150 KVA ± 25%

 

Enclosure 336H
1880W x 1480H x 660D (mm)
400 KVA ± 15%
250 KVA ± 20%
180 ~ 200 KVA ± 25%

 

Enclosure 337H
1880W x 1950H x 880D (mm)
500 KVA ± 15%
300 KVA ± 20%
250 KVA ± 25%

 

Enclosure 339H
2170W x 1950H x 1340D (mm)
600~1,000 KVA ± 15%
400~600 KVA ± 20%
300~400 KVA ± 25%

Single Phase

SES-H-S Model
Added I/P Breaker Protection
1 to 100 KVA

Enclosure 102
270W x 460H x 490D (mm)
≤ 20 KVA ± 30%
≤ 15 KVA ± 20%
≤ 10 KVA ± 25%
≤ 10 KVA ± 15%

Enclosure 103
400W x 580H x 500D (mm)
25 KVA ± 15%
20 KVA ± 20%
15 KVA ± 25%

Enclosure 332
380W x 670H x 780D (mm)
30 KVA ± 15%

Enclosure 333
490W x 800H x 990D (mm)
40 ~ 50 KVA ± 15%
25 ~ 30 KVA ± 20%
20 ~ 25 KVA ± 25%
15 ~ 20 KVA ± 30%

Enclosure 334
540W x 900H x 1000D (mm)
60 ~ 75 KVA ± 15%
40 ~60 KVA ± 20%
30 ~ 50 KVA ± 25%
25 ~ 40 KVA ± 30%

Stay Safe With Greater Protection

As safety is our utmost priority, Ashley Edison prepares for every scenario possible
—taking the puzzle out of your protection.

Designed And Engineered With Safety In Mind

We leave nothing to chance when it comes to larger capacity units (≥400KVA). By installing high-quality protective acrylic shields in front of live parts, we ensure the safety of your personnel at all times. For enhanced protection during installation, all distances between uninsulated metal parts, busbars, and cable sizes are compliant with IEC61439-1 and IEC 61439-2 guidelines.

Outfitted with fireproof cable trunking, this protective solution safeguards against long fire exposure even in hazardous areas and explosive atmospheres—providing maximum safety for mission critical applications.

Fuss-Free Installation. Seamless Operations.

To ensure ease of installation, Ashley Edison addresses the concerns of contractors and installers by keeping it simple.

Internal-AVR

ALL TERMINATION POINTS ARE MANUFACTURED FOR EASY ACCESS

We keep the installation process simple and streamlined by allowing sufficient working space for installers. Taking the nut and bolt intrusions into consideration, we ensure that the distance between the uninsulated metal parts, the busbars, and cable sizes are compliant with IEC61439-1 and IEC 61439-2 guidelines.

 

Even in units with larger capacities, all busbar terminals are clearly marked out, and well positioned in line for easy identification of individual input and output terminations. Installation of these terminations are similar to those practised in high voltage transformers.

Easy Maintenance

Annual Ocular Maintenance
Visual Inspection 230
#1

Conduct Visual Inspection On Voltmeter:

Ensure reading is set to your desired set output voltage value (e.g. 230V).

LED Status
#2

Ensure LED Status Indicators are at “Normal”.

Subtxt LogoAsset 62 RGB
#3

Visual Observation Of Variable Transformer Surface:

Use airbrush for dusty environments if necessary.

Subtxt LogoAsset 72 RGB
#4

Visual observation if carbon brush is not worn out.

Moving Motor
#5

Conduct visual inspection to check variable transformers are all regulating (moving).

AE-MBB-PCB-Card-dark

Accuracy. Beyond Imagination.

The digitally enhanced Ashley Edison MBB Card ensures pinpoint voltage stabilisation against the most erratic anomalies, allowing you to protect precious uptime, effortlessly. Harnessing ultra precision capabilities to produce some of the tightest output voltage tolerance available in the industry, the Ashley Edison MBB Card delivers ±0.5% voltage accuracy, enabling your load equipment to enjoy optimal voltage supplies, regardless of load change in your electrical system.

Expert Digital Control

Utilising the advantageous measurements of true RMS, the Ashley Edison MBB Card’s reads both perfect, sinusoidal waves, as well as complex, distorted non sinusoidal waves—up to 0.1V accuracy. Coupled with lightning fast response time of 1.5ms, this expert digital control feature equips your load with total voltage protection that is precise, continuous and ultra responsive.

AE Digital Control Display_230v

Universal Presettable Function

The Universal Presettable Function onboard the Ashley Edison MBB Card allows seamless control of your desired output voltage value on all 3 Phases—with just a touch of a button. This multifunctional feature enables each AVR to fully operate with just 1 card, instead of separate cards for each individual phase. Fitted LED Output Voltmeter Display and Alert Indicator better facilitates easy status monitoring while performing maintenance on your AVR.

AE MBB Card

Microcontroller Unit (MCU)

MicroController Unit (MCU) helps you to deliver high speed and reliable efficiency in the AVR’s operations with less heat generation and reduced power consumption. Used in Supercomputers, Surface Mount Technology (SMT) allows components in the Ashley Edison MBB Card to be aligned closer together, creating a more compact and lightweight end product. Additional safety wire-to-board feature establishes fail-proof connectivity between circuits—so you can work safely on your AVR.